Electrical box, integrated flange and cover mechanisms

ABSTRACT

A “no profile” electrical box, integrated flange/protective assembly and interchangeable cover that obscures standard electrical outlets such that a wall surface appears nearly continuous, uninterrupted by the outlet or cover when in use or not in use. The profile of the combined unit equals only the thickness of the material from which it is constructed; no hinges, screws or fasteners of any kind are visible and no part of the assembly requires detachment or storage when the outlet is in use, as the hinged cover is undetectably stored in the electrical box, or may be used to cover the electrical cords when engaged in the outlet. Exemplary embodiments of the cover obscure the electrical outlet. Together, the electrical box and flange assembly allow the electrical outlet to be flush mounted or recessed interchangeably, even after installation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to mechanisms for mounting electricaloutlets.

2. Description of the Related Art

Techniques for mounting and covering standard electrical outlets areinnumerable. Most variations concern one of three themes, (i) safety forsmall children, (ii) aesthetics or (iii) recession for electrical cordmanagement. Despite the abundance of related art in this sector,practically all indoor electrical outlet boxes and covers sold in theUnited States are of traditional design, with little of the patentedderivatives finding any level of commercial appeal. The failure ofcurrent designs to penetrate the commercial market results from thefollowing:

-   -   i) In terms of safety: obtrusive aesthetic design, excessive        manufacturing cost or difficulty in installation. Electrical        outlet installation is generally permanent in nature, while        children's safety is required only periodically and temporarily.        Safety features impede normal access to outlets in such a manner        as to deter the housing developers from incorporating permanent        inconveniences to a majority of customers on behalf of a        minority of customers. Also, the construction necessary to        retrofit an outlet for this temporary purpose is cost        prohibitive and impractical. Therefore add-on temporary products        such as plastic electrical outlet safety caps dominate the        marketplace.    -   ii) In terms of aesthetics, most designs, (a) amount to a        derivative of a cap that protrudes from the wall, clearly        visible and therefore creating limited appreciable aesthetic        benefit, (b) incorporate covers that either require storage        elsewhere when the outlet is in use or that are more obtrusive        when the outlets are in use than cover-free outlets, (c) require        excessive manufacturing cost, (d) require additional labor for        the home and office contractors.    -   iii) In terms of recessed outlet design, (a) too many electrical        devices utilize low voltage transformers or other plugs that a        recessed outlet will not accommodate, thereby preventing        prevalent installation, (b) a recessed design that fails to        incorporate aesthetic closures and easy closing mechanisms        offers limited benefit outside of special applications. As a        result, installations of such designs are relegated to specialty        uses such as wall-mounted audio visual equipment.

Home builders recognize the aesthetic detraction of standard outlets, asevidenced by the increasing practice of obscuring kitchen outletsthrough under-cabinet mounting, despite more difficult access forconsumers. Such mounting preserves the clean, uninterrupted visualappearance of a kitchen wall. However, no other room in a home or officebuilding offers such a means of obscuring the electrical outlets in amanner that would preserve the aesthetics of an un-breached wall. Thelack of commercial penetration by electrical boxes other than ofstandard design is evidence that no current design has incorporated thefour necessary elements:

(i) aesthetically appealing design,

(ii) user-friendly mechanical operation that provides easy access to theoutlet,

(iii) competitive manufacturing cost, and/or

(iv) the same field installation steps as used for standard boxes andcovers,

In terms of aesthetic improvement referenced in (i) above, the outlet,when not in use should closely resemble the surrounding wall. Featuresthat can improve the aesthetic appearance so include (a) minimal profilesuch that difference in depth is difficult to perceive, (b) no exposedscrews or hinges, (c) limited gaps around the cover closure and (d)paintable material to be painted the same color as the drywall.

Proper mechanical operation referenced in (ii) above, requires that theoutlet not be particularly more difficult to access than are standardexposed outlets, can be accessed with one hand while holding anelectrical plug and/or must not require the removal and storage of adetachable cover.

As referenced in (iii) above, the parts used for mechanical operationand the general design as a whole cannot be significantly more expensiveto manufacture than standard boxes and cover plates.

Installation of the box, flange and cover in new construction must beconsistent with current practice as referenced in (iv) above, requiringno additional labor, time, or skills to install.

A design that sufficiently incorporates any of the individual elementswould be unique. A design that incorporates all elements in combinationwould be additionally unique. However, no prior art has produced designsof any one of these elements sufficient to penetrate the currentmarketplace with these individual attributes and particularly incombination with one another.

SUMMARY OF THE INVENTION

The present invention is a multi-configured electrical box, integratedflange and various cover mechanisms. Each feature of themulti-configured electrical box, flange and cover represent a separateembodiment and each design can be independent of, and freely combinablewith, the others. An object of the present invention is to obscureelectrical outlets in new construction and remodeling such that when notin use, they are generally indistinguishable from the surrounding walland when in use are no more, or are less prominent than standarduncovered outlets. Also, by obscuring and covering outlets, theinvention provides a level of safety for children and provides energysavings. Although the information herein, including the DetailedDescription, concerns the concealment of electrical outlets, the presentinvention could be readily adapted to cover any type of outlet includinga phone jack, cable outlet, or other outlet as understood by one ofordinary skill in the art. Furthermore, while such electrical outletsare generally described as adjoined by a drywall surface, the inventionis not so limited and may be installed, for example, on floors, ceilingsand at other desirable locations having a variety of surface materials.

The electrical box integrates and incorporates various cover mechanismssuch that covers are unseen when the outlet is in use and certainmechanisms obscure the connection between the electrical plugs andoutlets when outlets are in use. One embodiment of the box is configuredto allow the electrical outlet to be mounted in a recessed andun-recessed position interchangeably before and after original outletinstallation. The box is vertically reversible and therefore capable ofmounting on either side of a 2×4 frame. The technique for installing thebox, cover and flange are virtually identical to those required forstandard outlets.

The integrated design of the electrical box, flange and cover obscurethe outlet when not in use. Other embodiments can obscure one outletwhen the other is in use, can obscure both outlets when in use, and/orcan be recessed inside the electrical box, undetectable when the outletis in use.

Different embodiments incorporate various closure mechanisms, including:spring loaded counterweight, gravity, flat magnet, spring-loaded magnet,detent, or track mounted sectional doors, each closure mechanismaccommodating the low-profile design of the cover and flange and isundetectable when the outlet is in use.

In the below embodiments of the present invention, the integrated flangecovers the drywall cutout for the electrical box, protects from exposedwires in the outlet, seals the gap between electrical box and drywallfrom which energy is lost, and aligns with the cover when the cover isclosed. In further embodiments, an interior compartment or wall furtherprotects from exposed wires in the outlet. The configuration andfastening mechanism allows no screws or hinges to be exposed and for theflange to protrude from the wall by only the width of the material fromwhich it is constructed. The alignment with the closed cover and the lowprofile design provide the illusion of no-profile cover flush with thewall.

The invention overcomes limitations of related art as follows:

1. Aesthetics: The protrusion of covered outlets when viewed from thefront and particularly from the side has significant affect on perceivedaesthetics. Second to color, depth of an object compared with itsimmediate surroundings most heavily influences its relative prominence.Depth is a perceptual process function involving three-dimensionalorganization of stimuli. Contributors to the perception of objectsinclude shadows, which indicate distance, linear perspective, theconvergence of parallel tracks or lines as they recede into the distanceand among others, retinal disparity—the differences among images on theretinas of the two eyes. In order to accommodate the effect that depthperception has on the prominence or obscurity of an object, the designof the invented item incorporates the lowest profile possible andalignment of all components via the relationship between the door,flange and wall. For example, specific embodiments may achieve a profileof 1 mm-2 mm (depending on the material used); however, the invention isnot limited to such a range. This depth to the wall averagesapproximately 900% less than that of related art. This is accomplishedby the integrated design of box, flange and cover as more thoroughlydescribed under Detailed Description.

Unlike prior art, the invention does not include exposed screws or otherfasteners, hinges, or the profile associated with these mechanisms.

When the outlet is in use, the cover remains attached to the unit.Through the hinge system of the box, the cover opens to one side andinside the box, obscured from view. This differs from prior art that,when the outlet is in use, includes (i) plates that slide over the wall,substantially increasing the prominence of the unit by increasing thearea covered by the outlet and its components, (ii) hinge systems thatprotrude out from the wall, causing the cover to rest partly over theelectrical plugs and therefore more prominent than are uncovered outletswhen engaged and (iii) removable covers that require storage.

2. Ease of access: Related art uses covers that impede access, removablecovers and other mechanisms that require two hands or two steps in orderto engage an electrical device with an outlet. The lack of marketpenetration by related art partly reflects that the marketplace will notsacrifice functionality for aesthetics, in addition to limited aestheticbenefits having been introduced. The cover of the invented item can beopened with one hand while holding the electrical cord. Once opened, thecover does not interfere with the effort to engage the electrical cordin the outlet and is then easily recessed into the wall with the samehand. The hinge and pocket for cover and closing systems are morethoroughly described under Detailed Description.

3. Child Safety. The lack of market penetration by related art that isprimarily designed for child safety reflects the inconvenience of use byother than children, the manufacturing cost to construct the units, andin some cases, difficult and time consuming installation. Conversely,the camouflage nature of the invented item reduces interest of childrenand the closing mechanisms can provide child safety without impeding useby others or adding cost.

4. Energy Savings. According to the U.S. Department of Energy's ‘EnergySavers Tips on Saving Energy and Money at Home’, two percent of airescapes through electrical outlets/switches. This occurs due to thespace between the drywall cut and the electrical box and through theoutlet sockets. The flange of the invented device seals the area betweenthe drywall and the electrical box. The cover of the invented devicecreates a barrier between the outlet sockets and the room. Together theflange and cover virtually eliminate this type of energy loss and do sowhether none, one, or both outlets are in use.

Other objects and features of the present invention will become apparentfrom the following detailed description considered in conjunction withthe accompanying drawings. It is to be understood, however, that thedrawings are designed solely for purposes of illustration and not as adefinition of the limits of the invention. It should be furtherunderstood that the drawings are not necessarily drawn to scale andthat, unless otherwise indicated, they are merely intended toconceptually illustrate the structures and procedures described herein.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view showing a flange and cover of the presentinvention.

FIG. 2 is a side view showing an electrical box, flange and cover of thepresent invention.

FIG. 3 is a front view showing an electrical box of the presentinvention.

FIG. 4 is a front view showing an electrical box of the presentinvention.

FIG. 5 is front view showing an installed flange with open cover.

FIG. 6 is a cutaway view of a flange of the present invention.

FIG. 7 is a view showing a closure mechanism and a cover of the presentinvention in a closed position.

FIG. 8 is a view showing an electrical box and a cover of the presentinvention at a midpoint between fully open and fully closed.

FIG. 9 is a view showing a cover of the present invention in an openposition.

FIG. 10 is a view showing an integrated hinge and cover of the presentinvention.

FIG. 11 is a front view showing an electrical box of the presentinvention.

FIG. 12 is a cutaway side view of an electrical box and track of thepresent invention.

FIG. 13 is a view showing a cover of the present invention.

FIG. 14 is a back view showing a cover of the present invention.

FIG. 15 is a view showing a cover of the present invention.

FIG. 16 is a view of a split side-by-side cover of the presentinvention.

FIG. 17 is a view showing a cover of the present invention.

FIG. 18 is a view showing a split over/under cover of the presentinvention.

FIG. 19 is a view showing a closure mechanism of the present invention.

FIG. 20 is a view showing a single cover.

FIG. 21 is a view showing cover attachment points of the presentinvention.

FIG. 22 is a view showing cover hinge nodules.

FIG. 23 is a view showing a hollow receptor of the present invention.

FIG. 24 is a view showing a receptor affixed to a flange and abutting acover of the present invention.

FIG. 25 is a view through a cover showing a receptor mount of thepresent invention.

FIG. 26 is a view showing a detent closure mechanism of the presentinvention.

FIGS. 27 and 28 are views showing an electrical box of the presentinvention.

FIG. 29 is a schematic showing a front view, side view and a rear viewof an electrical box of the present invention.

FIGS. 30 and 31 are views showing a flange of the present invention.

FIG. 32 is a schematic showing a front view, side views and a rear viewof a flange of the present invention.

FIG. 33 is a view showing a door of the present invention.

FIG. 34 is a schematic showing side views and a rear view of a door ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiment modes of the present invention are explained below withrespect to the drawings. However, implementation of the presentinvention can be achieved in various different modes and withmodifications readily understood by those of ordinary skill in the art.Therefore, the present invention should not be construed to be limitedto specific embodiments of the present invention, including universalbox configurations or other integrated designs.

Embodiment 1

FIGS. 1 and 2 show the fully assembled unit, front and side view,installed with cover closed. The flange 1 surrounds and integrates theunit into the surrounding drywall 2. Cover 3 is closed with only theoutline 4 of the intersection of the flange and cover being visible. Theelectrical box 5 shown in FIG. 2, which is an integral component of thepresent invention, is obscured in FIG. 1 and the electrical outlet isobscured in FIGS. 1 and 2.

FIG. 3 shows the electrical box 5 having a height of 4.25″. The singlecover is retracted into the open box and only the leading edge 6 of thecover is exposed.

Top mounting plates 7 and 9 and bottom mounting plates 8 and 10 includeelectric outlet stabilizing tabs 11. On standard electrical boxes, thestabilizing tabs of the outlet rest on the outside edge of the box andextend beyond the top and bottom of the box.

According to one example of this embodiment, top mounting plate 7 andbottom mounting plate 8 may be formed, for example, recessed 1.75″ inelectrical box 5 to allow outlet 12 to be installed such that the faceof outlet 12 is recessed approximately 1.5″ from the front edge ofelectrical box 5.

According another example of this embodiment, top mounting plate 9 andbottom mounting plate 10 may be formed, for example, recessed ¼″ inelectrical box 5 to allow outlet 12 to be installed such that the faceof outlet 12 is recessed approximately ⅙″ from the front edge ofelectrical box 5. Furthermore, electrical box 5 is formed having a widthsufficient to accommodate side by side outlets.

The dual mounting configuration of electrical box 5 allows outlet 12 tobe mounted in electrical box 5 over top mounting plate 7 and bottommounting plate 8 in order to be fully recessed, or over top mountingplate 9 and bottom mounting plate 10 in order to be slightly recessedand is interchangeable during initial home or of installation, or evenafter initial installation.

By recessing outlet 12 inside the electrical box such that face ofoutlet 12 is recessed in accordance with this first embodiment, singlevertical cover when closed, will align flush with flange 1, which isflush with the wall on which electrical box 5 is installed and separatedonly by the thickness of the material from which flange 1 isconstructed. For the purpose of simplicity, all electrical boxessubsequently shown in this application are “single gang boxes” with onlyone set of mounting brackets.

FIG. 4 shows a front view of electrical box 5 without the outlet 12installed. The invention's second interior wall 13 attaches to the backwall of the electrical box 5 and continues toward the front edge of theelectrical box to the approximate depth of the bottom of the electricaloutlet when installed. This creates a channel into which the cover inembodiments 2 and 3 may recede into the box without interference byelectrical wire entering and/or exiting the electrical box. It alsoserves to separate the electrical connections from the flange opening,in accordance with Underwriters Laboratories safety specifications.Interior wall 13 would be included on any one or all four walls of theelectrical box, depending on the intended cover configuration. Theproximity of each interior wall 13 to the knockout tabs 14 for entry andexit of electrical wires into and out of the electrical box is shown.Guide tabs 5A are recessed from the leading edge of the electrical boxby a depth determined by the thickness of the drywall. It extends forapproximately 1.5″ perpendicular to the box, which is the approximatewidth of a 2×4 wooden stud. This provides for more consistent mountingof the box on a wooden stud than do the small notches on standard boxeswhich can be affected by the rounding of the corners of many 2×4s. Thedepth of the box in relation to the drywall is significantly more acutein this integrated design than with standard boxes and covers.Consistent mounting of the box in relation to the drywall is required inorder for the cover, when closed, to align flush with the flange whichis almost flush with the drywall, in keeping with the objective of theintegrated design, to obscure the outlet. Guide tabs 5A may beincorporated into each of Embodiments 1-4.

FIG. 5 shows the flange 1 to be used with the electrical box (notshown). Outlet 12 is in either mounting position 7/8 or 9/10 aspreviously outlined in FIG. 3.

The flange 1 rests flush on the drywall 2 protruding from the wall onlyby the width of the material from which it is constructed. The flange 1crosses the plane defined by the front of the electrical box (not shown)and immediately recesses into the electrical box at point 15 to a depththat is relative to the positioning of the outlet, 7/8 or 8/10 asindicated in FIG. 3. The flange 1 continues from both ends toward thecenter of the electrical box and is attached at the center screw 16 ofoutlet 12. In this manner, the flange protects the electrical wires andscrews on each side of the receptacle. The connection mechanism of theflange at the center screw 16 in either outlet position 7/8 or 9/10 isobscured when the cover is closed. The flange is therefore onecontinuous unit, except that the portion of the flange on the hinge sideof the electrical box stops as it crosses the plane of the electricalbox (not shown) at position 17, providing a channel for the cover inembodiments 2 and 3. Only the leading edge 6 of the open cover isexposed. When the cover is closed, the flange 1 at position 17 abuts andis flush with the trailing edge of the cover (not shown). FIG. 5 shows aflange configuration for a single cover, hinged on the left side ofelectrical box. However the cover and flange could be configuredsimilarly for hinging at the right, bottom, or top of electrical box, orany combination. Ground Fault Interrupter (“GFI” plugs) are configuredin the same manner except that the attachment points of the flange wouldbe at the top and bottom of the stabilizer mounts on the GFI plug 7/8,9/10 respectively, as shown on FIG. 3, because center screws are notincorporated into GFI outlets.

FIG. 6 shows a cutaway view of the flange 1, extending approximately ½inch over the drywall 2 cutout for the electrical box 5, on all foursides. The flange 1 enters the electrical box 5 on one to three walls ofthe electrical box depending on cover configuration. It would not extendinto the electrical box on the hinge side(s) of the electrical box, asshown in FIG. 5. On all sides, the flange 1 extends toward the outlet12, protecting the electric wiring.

FIG. 7 shows the first embodiment of the closure mechanism of theelectrical box 5. The electrical box is viewed from the bottom, withcover 3 in the closed position. The hinge 18 and cover 3 are formed asone molded or injected piece and are attached to electrical box 5 at 19and on the opposing side of electrical box 5. Note that the hinge can beattached to the interior or exterior of the electrical box. The wirespring 20 is attached to hinge 18 at 21 and to electrical box 5 at 22.The expanded view of wire spring 20 shows its shape, which includes aportion 20A, a minimal offset 20B and opposing 180 degree bends at 20Cand 20D. This spring holds the cover closed when cover is closed andholds the cover open when cover is open and it prevents cover from beingleft partially open where it could be damaged by people or animalswalking by the outlet. The hinge and spring act as a counterweight,allowing the cover to be opened by pressing the cover 3 at 23,eliminating the need for a handle or finger hole to open cover,supporting the purpose of the design which is to provide the appearanceof an uninterrupted wall and obscuring the outlet. The electrical box 5is angled at 24 to allow the cover to rotate down as further shown inFIGS. 8 and 9.

FIG. 8 shows the electrical box 5, viewed from the bottom with cover 3at the midpoint between opened and closed. The tab 25, extends from theleading edge 6 of cover 3, allowing cover, when open and recessed, to belifted, and it is obscured when cover is closed, further supporting theintention of the design to provide the appearance of an uninterruptedwall.

FIG. 9 shows the cover 3 in the fully open position. In this position,the hinge 18 is attached to the outside of electrical box 5 at 19 andthe cover rests outside the electrical box 5. If the hinge 18 isattached inside of the electrical box 5 at 19, the cover rests insidethe electrical box 5. Whether the hinge is mounted outside or insideelectrical box 5, only leading edge 6 is exposed when cover is open, asalso shown at 6 of FIG. 5. The box is angled at 24, as also shown inFIG. 7.

FIG. 10 shows the construction of integrated hinge and cover such thatthe hinge attached to an electrical box at connection point 19, anglesapproximately 90% at 25, then angles approximately 90% at 26.

Embodiment 2

FIG. 11 shows an electrical box according to a second embodiment of thepresent invention. The electrical box 5 in Embodiment 2 is substantiallysimilar to the electrical box in Embodiment 1; however, the closuremechanism differs. The closure mechanism in Embodiment 2 is formed asdual tracks 27 and 28 built into the electrical box, in which asectional door, attached to a roller, shall be inserted, much like avertically operated garage door and track. This door (or cover) retractsinto the electrical box, which is designed to accept the door due to thebox width, internal hinge tracks, and interior box wall (not shown) thatprevents interference from electrical wires inside the box, each morefully described under FIG. 4. When combined with the cover configurationshown in FIG. 13, the electrical outlet is obscured when not in use.Tracks 29 and 30 would support a horizontal (close across) closureutilizing the closures shown in FIG. 15 or FIG. 16. Screw holes 31 and32 for outlet attachment to electrical box 5 would be attached to box 5behind tracks 29 and 30 so not to interfere with cover movement.

When tracks 29 and 30 are used and when combined with outlet positioning7/8 in FIG. 2, and when combined with a split side-by-side cover asshown in FIG. 17, the connection point between the electrical wire andthe electrical outlet is obscured, even when an electrical plug isengaged, providing the visual effect of electrical wires entering awall.

Tracks 27 and 28, when utilized in conjunction with cover shown in FIG.18 and with outlet position 7/8 or 9/10 in FIG. 3, a single outletconnector may be covered while the other outlet connector is in use.

In each configuration, covers are stored in the electrical box when theoutlet is in use, obscuring them from view.

FIG. 12 shows a cutaway side view of electrical box 5 and track 28supporting a vertical closure. An opening 33 in track 28 allows for theinsertion of the rollers attached to the cover. A similarly styledinsertion point would be utilized for tracks 27, 29 and 30 shown in FIG.11.

FIG. 13 shows a single vertically closing cover 34 constructed invarious sections 35 and attached to rollers 36 that would mount into thehinge tracks 27 and 28 in FIG. 11.

FIG. 14 shows the back of cover 34 shown in FIG. 13 with hinges 37 ateach section 35, holding the sections together allowing the cover tofollow a curved track 28 of FIG. 12,

FIGS. 15-18 show various cover configurations that would integrate withvarious cover track configurations in the second embodiment of theelectrical box.

FIG. 15 shows a single cover that would mount into the hinge tracks 29and 30 shown in FIG. 11. The door, built in panels or sections 35, allowit to follow in the curved tracks 29 and 30 in FIG. 11. Each cover inFIGS. 15-18 incorporate the same sectional design, though not shown.

FIG. 16 shows a split side-by-side cover that would mount into the hingetracks 29 and 30 shown in FIG. 11. This configuration would beincorporated with recessed outlet positioning 7/8 in FIG. 3, obscuringthe electrical plugs and outlet, even when in use.

FIG. 17 illustrates a close up view of the cover illustrated in FIG. 16,incorporating cutouts 38 for electrical cords engaged in the outlet.Spring-loaded sliding plates on the back side of each cover wouldobscure cutouts 38 when the outlet is not in use.

FIG. 18 illustrates a split over/under cover for use in hinge tracks 27and 28 in FIG. 11, allowing one outlet to be covered while the other isin use.

Embodiment 3

FIG. 19 shows Embodiment 3 of the closure mechanism incorporated intothe electrical box 5. The electrical box 5 in Embodiment 3 issubstantially similar to the electrical box in Embodiments 1 and 2;however, the closure mechanism differs. The top mounted hinge tracks 39and bottom mounted hinge tracks 40 are built into the electrical box 5,can receive cover hinges shown in FIGS. 20 and 21, and are formed ononly one side of the electrical box 5, rather than three sides inEmbodiment 2.

Tracks 41/42, when combined with 39/40, can receive split side-by-sidecovers. Tracks 43/44 provide a single vertical (close down) coverconfiguration and when utilized with tracks 45/46 and a split verticalcover, a single outlet may be obscured while other outlet is in use.

The invented electrical box could accommodate all or any one of theabove configurations.

FIGS. 20 and 21 show that Embodiment 3 is configured to integrate solid(non-sectional) covers attaching only at cover hinge nodules 47 and 48on the trailing edge 49 of the cover 3. The attachment points could bepositioned at the bottom or top, or the left or right of all sides ofcover 3, depending on the intended track configuration of electrical boxas described in FIG. 19. The leading edge 6 of cover 3 is unattached tohinge tracks and therefore requires a separate closing mechanismincluding magnets or detents to hold it in place when closed.Conversely, Embodiment 2 includes a sectional cover attaching at fourpoints to a curved track and therefore does not need a separate closuremechanism to hold it in place when closed.

FIG. 22 illustrates the shape of the cover hinge nodules 47 and 48. Asshown in details A and B, the hinge is positioned on the inside of thecover such that the profile of the hinge would not exceed that of thecover and would not protrude from the drywall or electrical box whencover is closed.

FIG. 23 shows hollow receptor 51 that will accept a flat magnet mount ora touch latch magnet mount.

FIG. 24 shows the position of the receptor 51 affixed to flange 1 andabutting cover 3.

FIG. 25 shows a see-through view through cover 3 to receptor 51 asdescribed in FIGS. 23 and 24 positioned at either 52 or 53, depending onthe cover configuration.

FIG. 26 shows a detent closing mechanism 54 built into cover 3 with anopposing detent 55 in flange 1.

Embodiment 4

FIGS. 27-34 show a further embodiment of the present invention. In FIGS.27 and 28, electrical box 60 is shown, which has been provided withmounting tabs 61 to allow the box to be installed or attached to astructure with minimized installation error (e.g., ensuring propermounting depth). Furthermore, electrical box 60 is optimally shapedhaving dimensions to comply with code specifications requiring specificcubic volume, while concurrently limiting or minimizing the size of anydrywall cut required to install the electrical box 60.

An electrical outlet may be mounted to screw holes tabs 62 such that theoutlet is attached within electrical box 60. Specifically, screw holetabs 62 are provided at a depth allowing an electrical outlet mountedsuch that an attached flange 65 (shown in FIGS. 30 and 31) intersectswith electrical box 60 in a manner that avoids displacement of theflange 65 by such screws. For example, when an electrical outlet ismounted to screw hole tabs 62 with dome screws, the depth of screw holetabs 62 is sufficient to allow intersection of the flange 65 and theelectrical box 60 having a finished fit and avoids rocking of the flange65.

Specifically, this embodiment as illustrated particularly in FIGS. 30-34provides an electrical outlet cover configured to be mounted andattached to an electrical outlet. The electrical outlet cover comprisesa main body 56 that includes front faceplate flange 65 defining agenerally planar top cover surface peripherally extending around acentral opening 57 therein and mounting plate 58 recessed inward fromthe generally planar top cover surface and located within the centralopening. Mounting plate 58 includes a mounting mechanism (screw hole 66)configured to mount the mounting plate 58 to the electrical outlet. Afirst opening 59 is configured to expose at least a portion of theelectrical outlet when mounted thereto and an elongated second opening67 is offset from or adjacent to the first opening 59 as shown.

A door pivot support mechanism defines a pivot axis located inward ofmounting plate 58 and includes a hinge receptor 68 and hinge portions69. A door or cover 70 (FIGS. 33 and 34) is pivotally attachable to thedoor pivot support mechanism (68/69) to move through the elongatedsecond opening 67 with rotational motion about the pivot axis defined byhinge receptor 68 between an open position and a closed position. In theopen position, the first opening 59 is exposed and the door is locatedsubstantially inward of the top cover surface of the main body 56. Inthe closed position, the door covers the central opening 57 and a topsurface of the door is substantially flush with the top cover surface ofthe main body 56.

Referring back to FIG. 28, electrical box 60 includes a first box cavity73 capable of receiving the electrical outlet therein and a second boxcavity 74 offset from and separated from the first cavity box 73 by adivider wall 63. Mounting structure (screw hole tabs 62) is configuredto fixedly mount the electrical outlet in the first box cavity 73.

Electrical box 60 (shown in FIGS. 27-28) also includes internal wall 63(shown in FIGS. 27-29), provided to separate wires connected to anoutlet terminal from interfering with the movement of door 70 (shown inFIG. 33). When an outlet is installed within electrical box 60, wiringconnected to the outlet is constrained to an inner portion of internalwall 63. Accordingly, even when door 70 (shown in FIGS. 33 and 34) orflange 65 (shown in FIGS. 30 and 31) is removed from electrical box 60,a connected wiring would remain partitioned by inner wall 63, to avoidunintended contact with the connected wiring. For example, if a childwere to remove either door 70 or flange 65 from electrical box 60,access to electrical connections would still be impeded by internal wall63, according to this embodiment of the present invention.

With an electrical outlet attached to electrical box 60 at screw holetabs 62, flange 65 is provided such that it can be attached theelectrical outlet through screw hole 66. Door 70 can be attached toflange 65 by coupling hinge nodule 72 of door 70 to hinge receptor 68 offlange 65. When attached to flange 65, door 70 can traverse door opening67, such that door 70 can be closed flush with flange 65 oralternatively retracted inside electrical box 60. Hence, both the flange65 and door 70 are adapted to, yet removable from, electrical box 60. Assuch, the attachment mechanism of each part is configured to ensure aconsistent relationship and finished fit, while also allowing easymaintenance or replacement of the individual parts, such as the flange65 and the door 70.

Furthermore, by coupling the flange 65 with the door 70 at hingeportions 69 and 71, respectively, instead of edge portions, theinterface of flange 65 and door 70 can be hidden within electrical box60 by the bevel and reverse bevel of flange 65 and door 70, so as tocreate a satisfying aesthetic appearance. In addition, the hingemechanism including hinge portions 69 and 71 is provided having a shapethat allows the hinge to rotate, yet intersect the flange at arelatively flat angle (that is, less than 90°). Accordingly, door 70 maybe opened and closed with minimal required clearance, such that anelectrical outlet installed within electrical box 60 may be safely andeasily accessed, for example, behind furniture and other objects thatare situated in front of the outlet, which embodiments 2 and 3 do notprovide.

A flange 65 according to this embodiment can be manufactured using“Finite Element Analysis” manufacturing techniques, which are known inthe art and not described herein, to allow production of flange 65 withextremely thin, yet durable, material. A flange 65 produced in thismanner will allow extreme tapering of the flange's intersection withsurrounding drywall (or other adjoining surface).

Furthermore, a flange 65 and/or a door 70 of this embodiment can beprovided with opening/closing mechanisms including, for example, akinematic push/pull opening mechanism or a spring assisted door, thatfacilitate the operation of the door. Such opening/closing mechanismallows the user access by pushing lightly on the hinge side of the doorand have it open fully, allowing one-handed access by a user with anelectrical chord in hand, which embodiments 2 and 3 do not provide. Italso can enhance the safety features of the present invention, forexample, by mechanically shutting a door 70 that is only partiallyopened and reducing the risk that door 70 is inadvertently opened orleft open.

This embodiment of the present invention therefore achieves additionalsafety and aesthetic advantages by integrating an electrical box, flangeand door, such that the door is easily accepted into the flange andinside the electrical box with minimal interference from within theelectrical box or by the attachment mechanism and minimal clearancerequired outside of the electrical box.

Each embodiment of the present invention described above can be furtheradapted and implemented in a variety of different combinations withmodifications readily understood by those of ordinary skill in the art.Therefore, the scope of the present invention is intended to becomprehended in accordance with the general knowledge of the art andshould not be construed to be limited solely to the above describedembodiments.

The invention claimed is:
 1. An electrical outlet cover, comprising: amain body including: a front faceplate flange defining a generallyplanar top cover surface peripherally extending around a central openingtherein; a mounting plate recessed inward from the generally planar topcover surface and located within the central opening, the mounting plateincluding: a mounting mechanism configured to mount the mounting plateto an electrical outlet; and a first opening configured to expose atleast a portion of the electrical outlet when mounted thereto; anelongated second opening offset from or adjacent to the first opening;and a door pivot support mechanism defining a pivot axis located inwardof the front faceplate flange at a distance from the plane of the frontfaceplate flange; and a door pivotally attachable to the door pivotsupport mechanism by hinge portions to move through the elongated secondopening with only rotational motion about the pivot axis between an openposition and a closed position, wherein in the open position, the firstopening is exposed and the door is located almost entirely inward of thetop cover surface of the main body, wherein in the closed position, thedoor covers the central opening and a top surface of the door is flatand substantially flush with the top cover surface of the main body,wherein the second opening is configured to accommodate the rotationalmotion of the door and hinge portions about the pivot axis between theopen position and the closed position, wherein the pivot axis is locatedalong a vertical plane at substantially the center of the centralopening taken parallel to the leading edge of the door in the frontfaceplate flange, and wherein the door is configured to be manuallymovable from the closed position by pushing on the door at a locationbetween the pivot axis and the second opening.
 2. The electrical outletcover according to claim 1, wherein all lateral sides of the door areentirely hidden from view by sides of the front faceplate flange whenthe door is in the closed position to provide a clean, visual appearanceof a wall.
 3. The electrical outlet cover according to claim 1, whereinthe electrical outlet cover is configured to be directly mounted to theelectrical outlet.
 4. The electrical outlet cover according to claim 1,wherein the second opening is C-shaped to accommodate rotation of thedoor and the hinge portions.
 5. The electrical outlet cover according toclaim 1, wherein structure necessary to achieve the rotational motion ofthe door about the pivot axis between the closed position and the openposition upon said pushing on said door consists of one of the door andthe door pivot support mechanism having a hinge receptor at the pivotaxis and the other having a hinge nodule at the pivot axis.
 6. Anelectrical box assembly comprising: an electrical box configured toattach to a wall, ceiling or floor, the electrical box including: afirst box cavity; a mounting structure configured to fixedly mount anelectrical outlet in the first box cavity; and a second box cavityoffset from and separated from the first box cavity by a divider wall;and an electrical outlet cover configured to be mounted and attached tothe electrical box, the electrical outlet cover comprising: a main bodyincluding: a front faceplate flange defining a generally planar topcover surface peripherally extending around a central opening therein; amounting plate recessed inward from the generally planar top coversurface and located within the central opening, the mounting plateincluding: a mounting mechanism configured to mount the mounting plateto the electrical box; and a first opening configured to expose at leasta portion of the electrical outlet when mounted thereto; an elongatedsecond opening offset from or adjacent to the first opening; and a doorpivot support mechanism defining a pivot axis located inward of thefront faceplate flange at a distance from the plane of the frontfaceplate flange; and a door pivotally attachable to the door pivotsupport mechanism by hinge portions to move through the elongated secondopening with only rotational motion about the pivot axis between an openposition and a closed position, wherein when the electrical outlet coveris mounted to the electrical box, the first opening is configured tooverlap with the first box cavity of the electrical box and theelongated second opening is configured to overlap with the second boxcavity of the electrical box, wherein in the open position, the firstopening is exposed allowing access to the electrical outlet and the dooris located almost entirely inward of the top cover surface of the mainbody within the second box cavity of the electrical box, wherein in theclosed position, the door covers the central opening and a top surfaceof the door is flat and substantially flush with the top cover surfaceof the main body, wherein the second box cavity and the second openingare configured to accommodate the rotational motion of the door andhinge portions about the pivot axis between the open position and theclosed position, wherein the pivot axis is located along a verticalplane at substantially the center of the central opening taken parallelto the leading edge of the door in the front faceplate flange, andwherein the door is configured to be manually movable from the closedposition by pushing on the door at a location between the pivot axis andthe second opening.
 7. The electrical box assembly according to claim 6,wherein all lateral sides of the door are entirely hidden from view bysides of the front faceplate flange when the door is in the closedposition to provide a clean, visual appearance of a wall.
 8. Theelectrical box assembly according to claim 6, wherein the electricaloutlet cover is configured to be directly mounted to the electricaloutlet.
 9. The electrical box assembly according to claim 8, wherein themounting plate comprises a hole configured to accept a screw, the screwmounting the electrical outlet cover main body directly to theelectrical outlet.
 10. The electrical box assembly according to claim 6,wherein the second opening and the second box cavity are C-shaped toaccommodate rotation of the door and the hinge portions.
 11. Theelectrical outlet cover according to claim 6, wherein structurenecessary to achieve the rotational motion of the door about the pivotaxis between the closed position and the open position upon said pushingon said door consists of one of the door and the door pivot supportmechanism having a hinge receptor at the pivot axis and the other havinga hinge nodule at the pivot axis.
 12. An electrical outlet cover,comprising: a main body including: a front faceplate flange defining agenerally planar top cover surface peripherally extending around acentral opening therein; a mounting plate recessed inward from thegenerally planar top cover surface and located within the centralopening, the mounting plate including: a mounting mechanism configuredto mount the mounting plate at least indirectly to an electrical box;and a first opening configured to expose at least a portion of anelectrical outlet when mounted thereto; an elongated second openingoffset from or adjacent to the first opening; and a door pivot supportmechanism, the door pivot support mechanism including a hinge receptordefining a pivot axis located inward of the front faceplate flange at adistance from the plane of the front faceplate flange; and a hinged doorincluding at least one hinge pivotally attachable to the hinge receptorof the door pivot support mechanism to move the hinged door through theelongated second opening with only rotational motion about the pivotaxis between an open position and a closed position, wherein in the openposition, the first opening is exposed and the door is located almostentirely inward of the top cover surface of the main body, wherein inthe closed position, the door covers the central opening and a topsurface of the door is flat and substantially flush with the top coversurface of the main body, wherein the second opening is configured toaccommodate the rotational motion of the door and the at least one hingeabout the pivot axis between the open position and the closed position,wherein the pivot axis is located along a vertical plane atsubstantially the center of the central opening taken parallel to theleading edge of the door in the front faceplate flange, and wherein thedoor is configured to be manually movable from the closed position bypushing on the door at a location between the pivot axis and the secondopening.
 13. The electrical outlet cover according to claim 12, whereinall lateral sides of the door are entirely hidden from view by sides ofthe front faceplate flange when the door is in the closed position toprovide a clean, visual appearance of a wall.
 14. The electrical outletcover according to claim 13, wherein the electrical outlet cover isconfigured to be directly mounted to the electrical outlet in theelectrical box.
 15. The electrical outlet cover according to claim 14,wherein the mounting plate comprises a hole configured to accept ascrew, the screw mounting the electrical outlet cover main body directlyto the electrical outlet in the electrical box.
 16. The electricaloutlet cover according to claim 12, wherein the second opening isC-shaped to accommodate rotation of the door and the at least one hinge.17. The electrical outlet cover according to claim 12, wherein structurenecessary to achieve the rotational motion of the hinged door about thepivot axis between the closed position and the open position upon saidpushing on said hinged door consists of the hinge receptor at the pivotaxis and a hinge nodule of the at least one hinge of the hinged door atthe pivot axis.